Beverage filter cartridge

ABSTRACT

Beverage filter cartridge comprising a cup having at least one sidewall; a cover sealed to the cup to form an interior; and a filter pod provided the interior and having a substance provided therein for brewing a beverage; wherein at least a portion of the sidewall comprises a helical channel extending the cup.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of International Patent Application No. PCT/NL2012/050596, filed on Aug. 31, 2012, which claims the benefit of priority to U.S. Provisional Application No. 61/530,682, filed on Sep. 2, 2011, all of which are hereby incorporated herein by reference in their entireties.

BACKGROUND

The present disclosure relates generally to the field of beverage filter cartridges, and more specifically, to disposable beverage filter cartridges usable with coffee machines or similar brewing devices to produce beverages such as coffee and the like.

SUMMARY

One embodiment relates to a beverage filter cartridge comprising a cup having at least one sidewall; a cover sealed to the cup to form an interior; and a filter pod provided within the interior and having a substance provided therein suitable for brewing a beverage; wherein at least a portion of the sidewall comprises a helical channel extending about the cup.

Another embodiment relates to a beverage filter cartridge comprising a cup having an open top, a closed bottom, and a sidewall extending between the top and the bottom, the top, bottom, and sidewall defining an interior; a filter disposed within the interior such that a space is maintained between the filter and the bottom; and a lid coupled to the top and configured to retain the filter within the interior; wherein the filter is not coupled to the cup or the lid.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a beverage filter cartridge according to an exemplary embodiment.

FIG. 2 is a cutaway perspective view of a cup for a beverage filter cartridge according to an exemplary embodiment.

FIG. 3 is a cross-sectional view of a beverage filter cartridge according to an exemplary embodiment.

FIG. 4 shows various filter pods according to exemplary embodiments.

FIG. 5 is a cutaway perspective view of a beverage filter cartridge according to an exemplary embodiment.

FIG. 6 is a schematic representation of a process for making beverage filter cartridges according to an exemplary embodiment.

FIGS. 7-14 are schematic representations of beverage filter cartridges and beverage filter cartridge components according to various exemplary embodiments.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Some commercially available brewing devices are configured to receive a disposable filter cartridge. The cartridge is inserted into a brewing cavity of the brewing device. The brewing device includes a brewing chamber to receive the cartridge, and access to the brewing chamber may be via a moveable handle, a cover, etc. A user places the cartridge into the brewing chamber of the brewing device and initiates the brewing process. A first piercing member of the brewing device penetrates the top of the cartridge and introduces a fluid, such as hot water, into the interior of the cartridge, which typically contains a substance such as coffee granules. The hot water passes through the coffee granules, extracting coffee flavoring from the coffee granules before passing through a filter material within the cartridge. A second piercing member of the brewing device pierces the bottom of the cartridge and provides an exit path for the brewed beverage to leave the cartridge and be directed to a cup or other container used for consumption by users.

Referring to the FIGURES generally, various embodiments disclosed herein are directed to beverage filter cartridges usable with brewing devices such as coffee machines to make, for example, single servings of coffee or other beverages (e.g., tea, etc.). As discussed in detail herein, the beverage filter cartridges of the present disclosure may provide several advantages over more conventional cartridges.

Referring now to FIGS. 1-5, a beverage filter cartridge 10 (e.g., a container, package, canister, pod, etc.) is shown according to an exemplary embodiment. Cartridge 10 is configured for use with a coffee machine or similar brewing device 20 such that, as further discussed herein, a top piercing member 22 of brewing device 20 pierces the top of cartridge 10 and provides a supply of a liquid (e.g., hot, pressurized water or other liquid, etc.), and a bottom piercing member 24 of brewing device 20 pierces the bottom of cartridge 10 and is configured to receive the brewed liquid (e.g., a coffee beverage) after passing through the interior of cartridge 10. Cartridge 10 may be usable with a variety of brewing machines, and is generally a disposable cartridge configured for one-time usage. Alternatively, cartridge 10 or one or more components thereof may be configured to be re-used by consumers (e.g., a reusable cup, etc.).

According to an exemplary embodiment, cartridge 10 includes a cup 12 (e.g., a container, holder, etc.), a filter bag, or pod 14 (e.g., a filter pod, filter assembly, etc.), and a lid 16 (e.g., a cover, top, film, foil, etc.). Generally, pod 14 holds a substance 18 (e.g., coffee grounds, tea, an additive, etc.) and is sealed within cup 12 by way of lid 16. According to some embodiments, cup 12 and lid 16 are sealed together such that they provide a sealed interior (e.g., via a hermetic seal, etc.) that maintains the freshness of substance 18 within pod 14. In some embodiments, the pod may be “compacted” within the interior of cup 12 when lid 16 is sealed to cup 12. Substance 18 may include substances such as coffee grounds/granules, tea, an additive (e.g., creamer, sugar, etc.) and the like, which are usable to extract flavorings, etc. into a liquid such as hot water to produce a brewed beverage. The substance may partially or totally dissolve in the liquid during the brewing cycle.

Lid 16 is a generally flat, planar member that is configured to seal, or adhere, to the upper portion of cup 12. In some embodiments, lid 16 may be or comprise a metal foil (e.g., aluminum, etc.), while in other embodiments, lid 16 may be or comprise a paper-based lid (e.g., cardboard, etc.). In some embodiments, a polymer material is integrated in with paper-based materials to facilitate melting/bonding (e.g., welding, etc.) of lid 16 to cup 12.

In some embodiments, lid 16 has an outer shape that generally conforms to or follows the shape of the upper portion of cup 12. Alternatively, one or more portions of lid 16 may overhang cup 12, e.g., to provide a pull tab, label, or other feature. Furthermore, lid 16 and/or cup 12 may include alignment features such as indents, detents, tabs, etc. configured to align cartridge 10 within device 20.

Pod 14 includes a filter 28 and substance 18. Filter 28 may be any suitable filter material used in brewing coffee and similar beverages (e.g., a paper-based filter material or the like). Filter 28 may be provided with a generally cylindrical shape to conform to the interior of cup 12. Substance 18 may include coffee grounds or any other suitable substance usable in brewing a beverage for consumption. Generally, as hot water passes through substance 18, a flavor (e.g., a coffee flavor, etc.) is extracted from the substance. In some embodiments, pod 14 includes a basket-shaped portion that receives the coffee grounds or other substance, and a generally flat top that is sealed to the basket portion. In some embodiments, pod 14 may be inserted into cup 12 “top down” to help ensure a relatively flat surface for top piercing member 22 to penetrate. In further embodiments, pod 14 may be partitioned to include separate compartments for different substances. For example, pod 14 may be configured such that a first compartment is filled with coffee grounds or granules, and a second compartment may be filled with an additive such as a creamer, sugar, etc. The shapes, relative sizes, and positioning of the compartments may be varied according to various alternative embodiments.

Cup 12 includes a top 30 and a bottom 32 with an annular sidewall 34 extending between top 30 and bottom 32. Top 30 may include a lip or flange portion 35 suitable for providing a surface to which lid 16 may be sealed, bonded, etc. Top 30 may be designed to facilitate insertion/removal of cartridge 10 to/from an appropriate brewing device (e.g., by providing a graspable portion, by providing alignment features, etc.). Bottom 32 may have a generally flat surface 33 surrounding a center stand-off 36 (e.g., a post, dimple, projection, raised portion, etc.). Sidewall 34 may include an annular rib 38 (e.g., an extension, a ridge, protrusion, etc.) and a helix portion 42 (e.g., a helical gallery or portion, spiraling portion, etc.) extending from below top 30 to above rib 38.

In some embodiments, it is desirable to maintain an empty space, or void 40 between the bottom of pod 14 and bottom surface 33 of cup 12. Void 40 permits hot water provided by top piercing member 22 to flow through and exit from pod 14, and further prevents bottom piercing member 24 from piercing pod 14, which could result in unwanted portions of substance 18 (e.g., coffee grounds) becoming mixed with the brewed beverage. In some embodiments, void 40 comprises approximately 20 percent of the interior volume of cup 12, while pod 14 takes up the remaining 80 percent of the interior volume of cup 12. In other embodiments, the relative volumes of pod 14 and void 40 may be varied to suit a particular substance being brewed, a desirable strength of beverage, etc.

According to an exemplary embodiment, cup 12 is configured to support pod 14 offset from surface 33 by way of center standoff 36 and/or annular rib 38 to provide void 40. In this way, pod 14 does not need to be coupled (e.g., sealed, etc.) to cup 12 or lid 16 in order to provide the appropriate space between the bottom of pod 14 and surface 33 of cup 12 to form void 40. In some embodiments, standoff 36 is sized to have cross-section large enough to not act like a needle and puncture pod 14, and small enough to allow a sufficient volume of brewed beverage to enter void 40 and not interfere with bottom piercing member 24.

In some embodiments, annular rib 38 may extend about the perimeter of cup 12 to assist in maintaining the position of pod 14 within cup 12. For example, annular rib may extend about cup 12 at a height such that pod 14 tends to rest on, or abut, annular rib 38, and the top of pod 14 is substantially even with top 30 of cup 12. While annular rib 38 is shown to have a generally rounded profile, other shapes and/or profiles may be used according to other exemplary embodiments (e.g., squared-off profiles, etc.). Furthermore, the position of annular rib 38 along the height of sidewall 34 may vary according to various exemplary embodiments.

According to an exemplary embodiment, helical portion 42 (e.g., a single helical or spiraling channel extending along all or a portion of the height of sidewall 34, a series of adjacent protrusions or channels, etc.) may extend from below/adjacent top 30 to above/adjacent annular rib 38. In some embodiments, helical portion 42 may extend along the entire height of sidewall 34. The number of “revolutions” of the channel forming the helical portion may vary according to various exemplary embodiments. According to various embodiments, helical portion 42 may provide several benefits to the brewing process, including generation of a cyclonic-pressure system around the perimeter of cup 12 that promotes even fluid distribution through substance 18. According to an alternative embodiment, sidewall 34 comprises a series of annular channels arrayed vertically along the sidewall rather than a single helical channel.

In some embodiments, helical portion 42 extends along sidewall 34 along the entire height of pod 14 when pod 14 is positioned within cup 12. In other embodiments, pod 14 may extend slightly below helical portion 42. Helical portion 42 is configured such that as hot water or other fluid passes through pod 14, the sides of pod 14 do not “stick” to, or completely conform to the grooves, or channels 44, of helical portion 42. In other words, the channels 44 of helical portion 42 are sufficiently deep that a fluid path is formed between pod 14 and sidewall 34 of cup 12 as hot water passes down through pod 14 and cup 12. As such, portions of fluid (e.g., hot water/coffee extract) may move downward through the pod/cup in a circular motion.

Furthermore, helical portion 42 creates a lower pressure region toward the outer portions of cup 12 (e.g. a “cyclonic pressure system” around the perimeter of the cup), thereby promoting a more even distribution/flow of liquid through the granules of substance 18. As a result, more efficient extraction from substance 18 may result relative to more traditional brewing techniques, providing a “stronger” beverage while using the same amount of substance/granules. In some embodiments, as fluid enters cartridge 10, the initial pressure of the fluid forces the fluid toward the sidewalls of cup 12. Pod 14 tends to “swell” due the introduction of the fluid, and pod 14 then tends to “grip” the helical portion of cup 12 such that the fluid flows in a circular motion (e.g., a circumferential flow path) around the helical portion of cup 12. Fluid may thus exit through the side and/or bottom of pod 14.

According to some embodiments, the helical portion of the cup provides a “crushable” cartridge that is configured to be crushed, or compacted post-use, thereby minimizing the volume of waste material for consumers. Furthermore, cup 12 may slightly compress during use, providing a visual indication to users that the filter has been used and may be discarded.

According to some embodiments, cup 12 may be made from a polymer material (e.g., polypropylene, etc.), such that cup 12 provides a barrier from moisture, oxygen, carbon dioxide, etc. during transportation, sale, etc. of cartridge 10 and maintains the freshness of substance 18 within pod 14. Bottom surface 33 of cup 12 is configured to be pierceable by an appropriate piercing member, or needle, such as bottom piercing member 24. In some embodiments, cup 12 may be a blow-molded or thermoformed component. In other embodiments, any other suitable manufacturing technique may be utilized in making cup 12 (e.g., injection molding, other forming processes, or combinations thereof).

Referring now to FIG. 4, pod 14 is shown according to an exemplary embodiment, and includes a basket 41 and a cover 43 that form filter 28 (discussed above) when holding substance 18. Basket 41 is a generally basket shaped member configured to hold a volume of substance 18 such as coffee grounds or granules, etc. Cover 43 is a generally flat member configured to be sealed to basket 41 to seal the substance within filter 28. In some embodiments, basket 41 and cover 43 may be made from the same or similar filter material (e.g., a paper-based filter material, etc.). As indicated above, the size, shape, and/or material of pod 14 may be varied to suit a particular application.

Referring to FIG. 6, a schematic representation of a process for producing a beverage filter cartridge such as cartridge 10 is shown according to an exemplary embodiment. First, cup 12 is formed. In some embodiments, cup 12 is formed from a polymer sheet of material in a forming machine. According to various other embodiments, cup 12 may be manufactured by injection molding, by injecting molding a perform that is then blow molded, or “stretched,” to its final shape, by extrusion blow molding, pressure thermoforming, combinations thereof, or other suitable processes. The formed cups are then transferred to a first, nested conveyor with recesses configured to receive the cups. A second conveyor may then be positioned to “drop” the pods (after being formed, filled with substance, and sealed) into the cups. The filled cups may then be sealed with an appropriate lid material (e.g., utilizing a sheet of lid material such as a foil or paper-based product), and the individual cartridges may then be individually trimmed for final packaging, labeling, etc. According to various alternative embodiments, additional and/or different steps may be performed in producing beverage filter cartridges than those shown in FIG. 6.

Referring to FIG. 7, a cartridge 110 is shown according to an alternative embodiment. Cartridge 110 is generally similar to cartridge 10 except as described herein. Cartridge 110 includes a cup 112 and a lid 116 sealed to cup 112 and having an aperture 115. A compacted filter 128 may be inserted into the interior of cup 112 and heat staked or otherwise bonded to the perimeter of aperture 115. Granules may then be inserted to the interior of the filter 128 such that the filter expands within the interior of cup 112. After inserting the granules, the top of cartridge 110 may be sealed with a sealing member 113 (e.g., a foil or paper seal).

Referring to FIG. 8, a portion of a cartridge 120 is shown according to an alternative embodiment. Cartridge 120 is generally similar to cartridge 10 except that cartridge 120 does not utilize an annular rib on the cup, but rather utilizes a number of discrete standoffs 121 to support the pod. Further, cartridge 120 does not include a central standoff or post extending upward from the bottom of the cup.

Referring to FIG. 9, a portion of a cartridge 130 is shown according to an alternative embodiment. Cartridge 130 is similar to cartridge 120, in that the cup includes a number of standoffs 131. Cartridge 130 further includes a central standoff or post 133. Standoffs 131, 133 are intended to support a pod (not shown).

Referring to FIGS. 10-14, alternative embodiments of cartridges are shown according to various exemplary embodiments, and may generally include similar features to the other cartridges discussed herein except as noted. For example, referring to FIG. 10, a cup 52 may be an injection molded polymer component having a pair of finger tabs 54 extending outward from the top portion of the cup. Finger tabs 54 may facilitate orientation of the cup within a cavity of a brewing device. A plurality (e.g. 4) of standoffs 56 may extend upward from the bottom to assist in supporting a pod. Utilizing finger tabs 54 to locate cup 52 within a brewing device may ensure that the location of the bottom piecing nozzle of the brewing device can be approximated and standoffs 56 may be properly sized/located so as not to interfere with the bottom piercing function of the brewing device.

An asymmetric helical portion 57 (e.g., such that the each individual groove or channel has a cross-section that “sags” or “slumps” downward) may aid in ejection from a suitable tool cavity (e.g., an injection molding tool), and the angle of the bottom edge of each channel of the helical portion may provide better gripping/support for pod 14. This embodiment provides a one-piece construction having integrated standoffs that support the pod without the need for any additional filter supports. Appropriate barrier properties (e.g., moisture, oxygen, etc. barriers) may be achieved by adding additives to an injection molding material, by spray-coating the internal surface with ethylene vinyl alcohol (EVOH), etc.

Referring to FIG. 11, a cup 62 is shown according to an exemplary embodiment. Cup 62 may be similar to cup 52 shown in FIG. 10 except cup 62 does not include any finger tabs and has a substantially flat bottom without any standoffs. A filter support 64 having a recessed central portion 68 may be disposed within cup 62 and support a pod to avoid penetration by the lower piecing member. Filter support 64 may be an injection molded component formed to support the pod and have a plurality of apertures 66 that permit the beverage to flow out of the pod. Utilizing filter support 64 may allow for a larger/deeper compartment usable for beverage preparation.

Referring to FIG. 12, a cup 72 is shown according to an exemplary embodiment. Cup 72 may be similar to cup 62 shown in FIG. 11, except that cup 72 includes a helical portion that tapers at a greater rate than other embodiments disclosed herein. Further, the bottom portions of the channels 77 forming the helical portion may have a sharper bottom portion to improve gripping of the pod and lower the risk of the filter material blocking the free channel down. The cup taper and shape of the helical portion may enable cup 72 to be injection molded and subsequently removed from the injection molding tool cavity without having to “unscrew” the molded component from the tool, as may be the case with other cup designs.

Referring to FIG. 13, a cup 82 is shown according to an exemplary embodiment. According to one embodiment, cup 82 is formed by initially injection molding a preform 84 and subsequently blow-molding cup 82 into its final shape. Cup 82 may be formed with a number of standoffs 86 (e.g., 4, etc.) such that a pod may be supported without any additional filter support components. Furthermore, cup 82 may be “stackable” prior to receiving a pod, which may save storage space during production of the cartridges.

Referring to FIG. 14, a cup 92 is shown according to an exemplary embodiment, Cup 92 may be made using a pressure thermoforming process (e.g., a plug-assisted thermoforming process, etc.) and includes a central standoff or post 94 extending from the center of the bottom. A generally flat filter support 96 (a disc-shaped member, etc.) having apertures 98 may rest upon post 94 and provide support for a pod and prevent puncturing of the pod by a piercing member of a brewing device.

The various embodiments of the cartridges disclosed herein may provide various advantages to users, including providing a package envelop that comfortably fits into, functions without leakage, and is removable from, various brewing devices; a cartridge that holds an appropriate volume of substance/granules (e.g. coffee), while being sealed against oxygen, moisture, and/or other undesirable elements; and a cartridge that further permits fluid to flow in a controlled environment and at a controlled flow rate (i.e., maintaining a sufficient brew chamber during operation) while preventing beverage granules from exiting the cartridge and entering the beverage. The cartridges further have a robust design for transportation and storage, are safe for handling (e.g., do not include any sharp edges or hot surfaces), and provide a beverage that is safe for consumption.

Various embodiments may further provide a barrier to protect the substance/granules from contamination and degradation prior to and during use, while providing top and/or bottom surfaces that are pierceable by appropriate brewing devices. The helical features of the cup evenly distribute fluid throughput across the substance/granules while providing a non-turbulent fluid exit flow from the cup into the machine.

It is important to note that the construction and arrangement of the elements of the beverage filter cartridges as shown in the exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the various embodiments. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and/or omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the spirit of the present disclosure. 

What is claimed is:
 1. A beverage filter cartridge comprising: a cup having at least one sidewall; a cover sealed to the cup to form an interior; and a filter pod provided within the interior and having a substance provided therein suitable for producing a brewed beverage; wherein at least a portion of the sidewall comprises a helical channel extending about the cup.
 2. The cartridge of claim 1, wherein the cup comprises an inwardly-extending annular rib.
 3. The cartridge of claim 2, wherein the cup comprises a post extending upward from a bottom of the cup.
 4. The cartridge of claim 3, wherein the filter pod is supported within the cup by the annular rib and the post to define a space between the filter pod and the bottom of the cup.
 5. The cartridge of claim 1, wherein the filter pod is not coupled to the cup and is not coupled to the cover.
 6. The cartridge of claim 5, wherein the filter pod contains the substance within an interior of the filter pod such that the substance is retained within the interior of the filter pod.
 7. The cartridge of claim 1, wherein the helical channel extends from adjacent a top of the cup.
 8. The cartridge of claim 1, wherein the helical channel extends from adjacent the top of the cup to adjacent the bottom of the filter pod.
 9. The cartridge of claim 1, wherein the helical channel is configured to generate an area of reduced fluid pressure when fluid is introduced into the cartridge by a brewing device.
 10. The cartridge of claim 9, wherein the helical channel is configured to direct at least a portion of the fluid to flow in a circular motion as the fluid flows downward through the cup.
 11. The cartridge of claim 9, wherein the cup and the cover are sealed to preserve the substance within the filter pod prior to use of the cartridge.
 12. The cartridge of claim 1, wherein the cup and cover are configured to be pierced by a brewing machine to permit fluid to flow through the interior of the cup and the filter pod to produce the brewed beverage.
 13. A beverage filter cartridge comprising: a cup having an open top, a closed bottom, and a sidewall extending between the top and the bottom, the top, bottom, and sidewall defining an interior; a filter disposed within the interior such that a space is maintained between the filter and the bottom; and a lid coupled to the top and configured to retain the filter within the interior; wherein the filter is not coupled to the cup or the lid.
 14. The cartridge of claim 13, wherein the sidewall comprises a helical portion extending adjacent the filter.
 15. The cartridge of claim 14, wherein the bottom comprises a raised portion configured to support the filter and maintain the space between the filter and the bottom.
 16. The cartridge of claim 15, wherein the sidewall comprises an annular rib extending at least partially about the perimeter of the sidewall. 